Modular composite intercooler

ABSTRACT

A modular heat exchanger assembly comprising: a plurality of interlocking housings each having a heat-exchanging element, a first and second side each having a mating connector and a first end and a second end, wherein the interlocking housings interlock to each other by the second side having a mating connector interlocking with the first side having a mating connector to provide a heat exchanger core, the first end has a plurality of first end mating connector openings and the second end has a plurality of second end mating connector openings; there may be at least one first-type end cap, at least one second-type end cap and/or at least one third-type end cap for connection to either one of the first end mating connector openings or one of the second end mating connector openings and there is at least one access opening.

This application claims priority to provisional patent application No.61/760,622 filed Feb. 4, 2013 and entitled “Modular CompositeIntercooler,” the entire contents of which are incorporated herein byreference.

The present invention relates to heat exchangers and in particular tomodular heat exchanger assemblies.

Conventional heat exchangers for use in automobiles utilize heatexchanging core elements which include a series of generally parallelaluminum tubes that are machined to shape and made of aluminum.

The present invention seeks to provide heat exchanger parts that may beinterchanged to provide a modular approach that can be used for everyavailable size and type of heat exchanger including, but not limited to,heat exchangers for cooling incoming air for engines, transmission fluidcoolers for vehicle transmissions, radiators for engine coolant. Also,the parts may be of plastic to reduce costs. The plastic also providesfor critical air seal to certain types of tubes (e.g. LAMINOVA™ tubes).Another advantage of the present invention is the reduction of, orelimination of, the need for tools to assemble the parts. Many of theparts may snap together without the need for tools.

These and other features, aspects and advantages of the presentinvention will become better understood with reference to the followingdescription and claims.

SUMMARY OF THE INVENTION

The present invention relates generally to modular heat exchangerassemblies.

According to one embodiment, a modular heat exchanger assembly isprovided comprising: a plurality of interlocking housings each having aheat-exchanging element, first side having a mating connector and asecond side having a mating connector and a first end and a second end,wherein the plurality of interlocking housings interlock to each otherby the second side having a mating connector interlocking with the firstside having a mating connector to provide a heat exchanger core andwherein the first end has a plurality of first end mating connectoropenings and the second end has a plurality of second end matingconnector openings; at least one first-type end cap with a plurality ofend cap mating connectors for connection to either one of the first endmating connector openings or one of the second end mating connectoropenings and having one first-type end cap open connector; at least onesecond-type end cap with a plurality of end cap mating connectors forconnection to either a first end mating connector opening or a secondend mating connector opening and having at least one second-type end capopen connector, wherein at least one first-type end cap open connectoris attached to at least one second-type end cap open connectors andwherein at least one of the at least one first-type end caps and the atleast one second type end cap has an access opening (38).

According to another embodiment, a modular heat exchanger assembly isprovided comprising: a plurality of interlocking housings each having aheat-exchanging element, first side having a mating connector and asecond side having a mating connector and a first end and a second end,wherein the plurality of interlocking housings interlock to each otherby the second side having a mating connector interlocking with the firstside having a mating connector to provide a heat exchanger core andwherein the first end has a plurality of first end mating connectoropenings and the second end has a plurality of second end matingconnector openings; at least one third-type end cap with a plurality ofend cap mating connectors for connection to either a first end matingconnector opening or a second end mating connector opening; at least onefirst-type end cap with a plurality of end cap mating connectors forconnection to either a first end mating connector opening or a secondend mating connector opening and having one first-type end cap openconnector, wherein at least two of the at least one first-type end capand the at least one third-type end caps have an access opening.

These and other features, aspects and advantages of the presentinvention will become better understood with reference to the followingdescription and claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 depicts a portion of the modular heat exchanger assemblyaccording to the present invention;

FIG. 2 depicts an exploded view of the modular heat exchanger assemblyaccording to the present invention;

FIG. 3 depicts one coolant flow path according to the present invention;

FIG. 4 depicts one coolant flow path according to the present invention;

FIGS. 5A, 5B and 5C depicts coolant flow paths according to the presentinvention;

FIG. 6 depicts an end cap according to the present invention;

FIG. 7 depicts an end cap according to the present invention;

FIG. 8 depicts an end cap according to the present invention;

FIG. 9 depicts an end cap according to the present invention;

FIG. 10 depicts an interlocking housing according to the presentinvention;

FIG. 11 depicts interlocking housings and a heat-exchanging elementaccording to the present invention;

FIG. 12 depicts a portion of the modular heat exchanger assemblyaccording to the present invention;

FIG. 13 depicts an end cap according to the present invention;

FIG. 14 depicts a mating connector according to the present invention;

FIG. 15 depicts a modular heat exchanger assembly according to thepresent invention;

FIG. 16 depicts a portion of an interlocking housing according to thepresent invention;

FIG. 17 depicts a portion of an interlocking housing according to thepresent invention;

FIG. 18 depicts an interlocking housing according to the presentinvention;

FIG. 19 depicts a portion of an interlocking housing according to thepresent invention;

FIGS. 20A and 20B depicts a modular heat exchanger assembly according tothe present invention;

FIG. 21 depicts an end cap according to the present invention;

FIG. 22 depicts a coolant inlet/outlet interface;

FIG. 23 depicts a coolant inlet/outlet interface;

FIG. 24 depicts a portion of an interlocking housing according to thepresent invention;

FIG. 25 depicts a portion of an interlocking housing according to thepresent invention; and

FIGS. 26A, 26B and 26C depict examples of mixed parallel and seriescoolant flow path.

DETAILED DESCRIPTION OF THE INVENTION

The following detailed description is of the best currently contemplatedmodes of carrying out the invention. The description is not to be takenin a limiting sense, but is made merely for the purpose of illustratingthe general principles of the invention, since the scope of theinvention is best defined by the appended claims.

With reference to FIGS. 1-25, the present invention provides a modularheat exchanger assembly comprising: a plurality of interlocking housings(10, 12, 14, 16) each having a heat-exchanging element (8), first side(18) having a mating connector (20) and a second side (22) having amating connector (24) and a first end (26) and a second end (28),wherein the plurality of interlocking housings interlock to each otherby the second side having a mating connector interlocking with the firstside having a mating connector to provide a heat exchanger core andwherein the first end has a plurality of first end mating connectoropenings (30) and the second end has a plurality of second end matingconnector openings; at least one first-type end cap (32) with aplurality of end cap mating connectors (34) for connection to either oneof the first end mating connector openings or one of the second endmating connector openings and having one first-type end cap openconnector (36). There may be at least one second-type end cap (40) witha plurality of end cap mating connectors (42) for connection to either afirst end mating connector opening (30) or a second end mating connectoropening and having at least one second-type end cap open connector (44,46), wherein at least one first-type end cap open connector (36) isattached to at least one second-type end cap open connectors (44) andwherein at least one first-type end cap and at least one second type endcap has an access opening (38). At least two end caps have an accessopening to permit the flow of coolant through the heat exchangerassembly—in effect, there needs to be one inlet and one outlet for everyheat exchanger assembly. In one embodiment, one of the second-type endcap open connectors (44) is an access opening.

In operation, the fluid that passes through the inside of the end caps(e.g. 32, 40) and heat exchanging element (8) (also referred to astubes) is a water/coolant mix that cools the exterior of the tubes andair is passing over the top and through the tubes. By way of example,the fluid may be air and water coolant, transmission fluid, refrigerant,engine oil, etc. passing both inside the heat exchanging elements andoutside and over the heat exchanging elements. The air passing over aheat exchanging element (8) (tubes) is hot and is cooled by thesignificantly lower temperature water/coolant passing through the heatexchanging element (8) (tubes). Two of the functions of the plurality ofinterlocking housings are to guide air over the tubes and to permit ameans to align and connect the caps to the tubes with a radial seal. Thehousings were designed in many different configurations withoutresorting to retooling to permit different juxtapositions of housings topermit different coolant flow methods. The tube is the heat-exchangerbody, the assembly taught herein creatively and cost effectivelyprovides a solution for providing a sealed coolant passage through theinside the tubes and an integrated ducting path for air flow over theexterior of the heat-exchangers for removal of heat from the incomingair.

It should be understood that there are many different end caps, whichmay be designed in a multitude of different ways to accomplish the goalsof providing different shapes, configurations and coolant flow paths.FIGS. 6, 7, 8 and 9 depict examples of different end cap configurations.According to one embodiment, the first-type end cap (32) has a pluralityof end cap mating connectors (34) for connection to either one of thefirst end mating connector openings or one of the second end matingconnector openings and having one first-type end cap open connector(36). The first-type end cap open connector (36) in the example shown isa male connector. The male connector, according to one embodiment, has aseries of concentric protrusions (98) with a raised portion (100) and acircular base (98). The connector may be a snap-fit or a series ofcantilever snaps, which permit disassembly. Such a connector requiresforce to unsnap, but does not break before disassembly. The second-typeend cap (40) may have a female connector (46) and a male connector (44).The first-type end cap open connector (36), shown as a male connector,fits into, or connects with/attaches to, the second-type end cap openconnector (46).

The second-type end cap (40) may have a female connector (46) and a maleconnector (44). The female connector (46) receives the first-type endcap open connector (36). The term “male” refers to the protrudingconnector and “female” refers to the recessed or open connector. The“male” part fits into the “female” part and may have a radial seal (102)therebetween. As depicted in FIG. 7, there may be second-type end cap(40) with a coolant flow cavity (110) between a male one way connector(112) and a female connector (114). As depicted in FIG. 6, for afirst-type end cap (32) there is a coolant flow cavity (116) between theend cap housing connector opening (106) and a male connector. Of course,as is the very purpose of the invention, the connectors can be changedand adjusted (e.g. a female one-way connector, a male one-way connector,a female connector, a male connector or any connection means) in any wayto suit the needs of the user.

The term first-type end cap (32) is intended to refer to an end cap thathas one first-type end cap open connector (36). The first-type end capopen connector (36) may be a female connector, a male connector, afemale connector, a male connector or any connection means. The termsecond-type end cap (40) has two second-type end cap open connectors.The second-type end cap open connectors (36) may be female one-wayconnectors, male one-way connectors, female connectors, male connectorsor any connection means known within the art. For example, thesecond-type end cap open connectors may be one male connector and onefemale connector. By way of another example, the second-type end capopen connectors may also be two male one-way connectors or two femaleone-way connectors.

The term third-type end cap (FIG. 3, 50) has no end cap open connectorsand only has the end cap housing connector opening (this may be seen inFIG. 9, on a first type end cap, as end cap housing connector opening104). FIGS. 6 and 9 depict first-type-type end caps. FIG. 6 shows endcap housing connector opening (106) for attachment to, or communicationwith, one of a plurality of interlocking housings (e.g. 10, 12, 14, 16),and in particular to the heat exchanger element (tube). It should benoted, that the end cap mating connectors (34) hold the end cap toeither one of the first end mating connector openings or one of thesecond end mating connector openings and having one first-type end capopen connector (36). This attachment may be seen in FIG. 12. FIG. 9shows end cap housing connector opening 104 for attachment to one of aplurality of interlocking housings (e.g. 10, 12, 14, 16).

According to another embodiment, there may be at least one third-typeend cap (50) with a plurality of end cap mating connectors forconnection to either a first end mating connector opening or a secondend mating connector opening. As can be seen in FIGS. 3 and 4, thethird-type end cap (50) does not allow for coolant flow to the adjacentend cap (52). Instead, the coolant flows directly into or out of theheat-exchanging element (see FIG. 1, heat-exchanging element 8 . . . ).In this way, a series coolant flow path (depicted in FIGS. 3 and 5B) anda mixed parallel and series coolant flow path (depicted in FIG. 5C, 26A,26B and 26C) may be accomplished. Of course, the male and femaleconnectors may be reversed without departing from the present invention.Also, any configuration and combination of different types of end capmay be used to accomplish the desired configuration. By way of example,the at least one second-type end caps (40) may be two second-type endcap open connectors that provide a parallel coolant flow path. Aparallel coolant flow path may also be achieved with at least onefirst-type end cap (32) attached to at least one second-type end cap(40). See FIG. 4 (and FIG. 5A) depicting a parallel coolant flow path.

Each of the second-type end caps (40) may also have two second-type endcap open connectors that provide a series coolant flow path. This isdepicted in FIG. 3. The plurality of interlocking housings each having aheat-exchanging element may also be connected to provide a mixedparallel and series coolant flow path. Examples of differentconfigurations that provide mixed parallel and series coolant flow pathare depicted in FIGS. 26A, 26B and 26C.

As shown in FIG. 12, there may be a number of o-ring seals (120)interposed between the plurality of end cap mating connectors (34) andat least one of the first end mating connector openings (30) and thesecond end mating connector openings (not shown in FIG. 12, would besimilar to first end mating connector openings (30), except at the otherend). There may also be an o-ring seal (122) interposed between aportion of the first-type end cap open connector and the second-type endcap open connectors. FIGS. 13-14 depict one embodiment of the end capmating connectors (34) and a first end mating connector openings (30).As can be seen, the end cap mating connector (34) has a slanted L-shapedprotrusion (130), such that it slides through the first end matingconnector opening and once it passes the opening the slated L-shapedprotrusion (130) prevents it from being removed while the part is beingassembled into a final end-item, although these protrusions can beserviced without damage if the manufacturers directions are followed.This helps to remove the need for tools and allows for easy snaptogether fit of the parts.

As shown in FIGS. 10, 11, 15 and 16, the plurality of interlockinghousings may have outer squared off corners to form a planar sealsurface for mating parts. FIG. 15 also depicts that the end caps(whether it is a first-type end cap, second-type end cap or third-typeend cap) may also have a square shaped base (124) and a planar edge(126) and although this surface is not used for sealing, it may permitadvantages in the assembly process. The planar seal surfaces for themating parts allow for easy alignment and for sealing of air to make theheat-exchanger efficiency improved when the assembly is used as in thefunction of an intercooler. The plurality of interlocking housings havea planar surface that permits the resulting surface to have aelastomeric element push against them forming a torturous path againstexternal airflow leakage around the tubes/housings, which if the leakageoccurred would make the heat-exchanger tubes less efficient. FIG. 11 isintended to show that the plurality of interlocking housings may be ofany desired length.

The plurality of interlocking housings, the at least one first-type endcaps, the at least one second-type end cap and the at least onethird-type end cap may be formed in a single piece or in multiplepieces. Each piece in the modular heat exchanger assembly of the presentinvention may be made of thermoplastic or thermoset materials and can beformed/made by injection molding, blow molding, casting, extrusionand/or compression molding. As shown in FIG. 16, the inside of thehousing can be pulled from both ends in the injection mold tool foroptimized shape control. The opening is drafted, except for this window(200), which is draft free to block air from bypassing theheat-exchanging element (8) (which may be, by way of a example, aLAMINOVA™ tube). The draft free window is toleranced so that it isalways in contact with the tube fins (202). FIG. 24 depicts theinterlocking housing formed in a single piece. FIG. 25 depicts theinterlocking housing formed in two pieces.

According to another embodiment, a modular heat exchanger assembly isprovided comprising: a plurality of interlocking housings each having aheat-exchanging element, a first side having a mating connector and asecond side having a mating connector (24) and a first end (26) and asecond end, wherein the plurality of interlocking housings interlock toeach other by the second side having a mating connector interlockingwith the first side having a mating connector to provide a heatexchanger core and wherein the first end has a plurality of first endmating connector openings and the second end has a plurality of secondend mating connector openings; at least one third-type end cap (50) witha plurality of end cap mating connectors for connection to either afirst end mating connector opening or a second end mating connectoropening; at least one first-type end cap (32) with a plurality of endcap mating connectors (34) for connection to either a first end matingconnector opening or a second end mating connector opening and havingone first-type end cap open connector (36), wherein at least two of theat least one first-type end cap and the at least one third-type end capshave an access opening (38). There may also be at least one second-typeend cap (40) with a plurality of end cap mating connectors (42) forconnection to either a first end mating connector opening (30) or asecond end mating connector opening and having at least one second-typeend cap open connector (44, 46), wherein at least one first-type end capopen connector (36) is attached to at least one second-type end cap openconnectors (44, 46). Note that a second-type end cap cannot be connectedto a third-type end cap, as a third-type end cap is closed on all sidesand must be adjacent to either another third-type end cap or afirst-type end cap. Accordingly, in any combination that includes athird-type end cap and a second-type end cap, there must also be afirst-type end cap interposed between the third-type end cap and thesecond-type end cap.

The plurality of interlocking housings each having a heat-exchangingelement may be connected to provide at least one of a parallel coolantflow path, a series coolant flow path and a mixed parallel and seriescoolant flow path. There may be o-ring seals interposed between theplurality of end cap mating connectors and at least one of the first endmating connector openings and the second end mating connector openings.FIGS. 20A and 20B depict an assembly sequence of the parts. First theplurality of interlocking housings (10, 12, 14, 16) are attached to oneanother, then the end caps (e.g. 32, 40) are attached. Of course, anytype of end cap may be used.

FIGS. 21-23 depict an access opening with a coolant interface. Theaccess opening of the end cap has pipe threads (208) which accept thethreaded pipe (206). FIG. 23 depicts one example of a hose interface(210).

It should be understood that the foregoing relates to preferredembodiments of the invention and that modifications may be made withoutdeparting from the spirit and scope of the invention as set forth in thefollowing claims.

We claim:
 1. A modular heat exchanger assembly comprising: a pluralityof interlocking housings each having a heat-exchanging element, a firstside having a mating connector and a second side having a matingconnector and a first end and a second end, wherein the plurality ofinterlocking housings interlock to each other by the second side havinga mating connector interlocking with the first side having a matingconnector to provide a heat exchanger core and wherein the first end hasa plurality of first end mating connector openings and the second endhas a plurality of second end mating connector openings; at least onefirst-type end cap with a plurality of end cap mating connectors forconnection to either one of the first end mating connector openings orone of the second end mating connector openings and having onefirst-type end cap open connector; at least one second-type end cap witha plurality of end cap mating connectors for connection to either afirst end mating connector opening or a second end mating connectoropening and having at least one second-type end cap open connector;wherein at least one first-type end cap open connector is attached to atleast one second-type end cap open connector; and wherein at least oneof the at least one first-type end caps and the at least one second typeend cap has an access opening.
 2. A modular heat exchanger as in claim1, wherein each of the at least one second-type end caps has twosecond-type end cap open connectors that provide a parallel coolant flowpath.
 3. A modular heat exchanger as in claim 1, wherein the pluralityof interlocking housings each having a heat-exchanging element areconnected to provide a parallel coolant flow path.
 4. A modular heatexchanger as in claim 1, wherein the plurality of interlocking housingseach having a heat-exchanging element are connected to provide a seriescoolant flow path.
 5. A modular heat exchanger as in claim 1, whereineach of the at least one second-type end caps has two second-type endcap open connectors that provide a series coolant flow path.
 6. Amodular heat exchanger as in claim 1, wherein the plurality ofinterlocking housings each having a heat-exchanging element areconnected to provide a mixed parallel and series coolant flow path.
 7. Amodular heat exchanger as in claim 1, further comprising an o-ring sealinterposed between the plurality of end cap mating connectors and atleast one of the first end mating connector openings and the second endmating connector openings.
 8. A modular heat exchanger as in claim 1,further comprising an o-ring seal interposed between a portion of thefirst-type end cap open connector and the second-type end cap openconnectors.
 9. A modular heat exchanger as in claim 1, wherein at leastone of the first-type end cap open connectors is a female connector. 10.A modular heat exchanger as in claim 1, wherein at least one of thefirst-type end cap open connectors is a male connector.
 11. A modularheat exchanger as in claim 1, wherein the at least one two second-typeend cap open connectors are one male connector and one female connector.12. A modular heat exchanger as in claim 1, wherein the plurality ofinterlocking housings have outer squared off corners to form a planarseal surface for mating parts.
 13. A modular heat exchanger as in claim1, wherein the plurality of interlocking housings, the at least onefirst-type end caps and the at least one second-type end cap are formedby injection molding.
 14. A modular heat exchanger as in claim 1,wherein at least one of the plurality of interlocking housings, the atleast one first-type end caps and the at least one second-type end capare formed in multiple pieces.
 15. A modular heat exchanger as in claim1, wherein at least one of the plurality of interlocking housings, theat least one first-type end caps and the at least one second-type endcap are formed in a single piece.
 16. A modular heat exchanger as inclaim 1, further comprising at least one third-type end cap with aplurality of end cap mating connectors for connection to either a firstend mating connector opening or a second end mating connector opening.17. A modular heat exchanger assembly comprising: a plurality ofinterlocking housings each having a heat-exchanging element, a firstside having a mating connector and a second side having a matingconnector and a first end and a second end, wherein the plurality ofinterlocking housings interlock to each other by the second side havinga mating connector interlocking with the first side having a matingconnector to provide a heat exchanger core and wherein the first end hasa plurality of first end mating connector openings and the second endhas a plurality of second end mating connector openings; at least onethird-type end cap with a plurality of end cap mating connectors forconnection to either a first end mating connector opening or a secondend mating connector opening; at least one first-type end cap with aplurality of end cap mating connectors for connection to either a firstend mating connector opening or a second end mating connector openingand having one first-type end cap open connector, wherein at least twoof the at least one first-type end cap and the at least one third-typeend caps have an access opening.
 18. A modular heat exchanger as inclaim 17, wherein the plurality of interlocking housings each having aheat-exchanging element are connected to provide at least one of aparallel coolant flow path, a series coolant flow path and a mixedparallel and series coolant flow path.
 19. A modular heat exchanger asin claim 17, further comprising an o-ring seal interposed between theplurality of end cap mating connectors and at least one of the first endmating connector openings and the second end mating connector openings.20. A modular heat exchanger as in claim 17, wherein at least one of thefirst-type end cap open connectors is either a female connector or amale connector.
 21. A modular heat exchanger as in claim 17, wherein theplurality of interlocking housings have outer squared off corners toform a planar seal surface for mating parts.
 22. A modular heatexchanger as in claim 17, further comprising at least one second-typeend cap with a plurality of end cap mating connectors for connection toeither a first end mating connector opening or a second end matingconnector opening and having at least one second-type end cap openconnector, wherein at least one first-type end cap open connector isattached to at least one second-type end cap open connectors.
 23. Amodular heat exchanger as in claim 22, further comprising an o-ring sealinterposed between a portion of the first-type end cap open connectorand the second-type end cap open connectors.